Safety Reference Manual - Rockwell Automation

1 GuardLogix Controller SystemsCatalog Numbers 1756-L61S, 1756-L62S, 1756-L63S, 1768-L43S,1768-L45S, RSLogix 5000 Version 20 and earlierSafety Reference ManualOriginal InstructionsImportant User InformationRead this document and the documents listed in the additional resources section about installation, configuration, and operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required to be carried out by suitably trained personnel in accordance with applicable code of this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be no event will Rockwell Automation , Inc.

2 Be responsible or liable for indirect or consequential damages resulting from the use or application of this examples and diagrams in this Manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation , Inc. cannot assume responsibility or liability for actual use based on the examples and patent liability is assumed by Rockwell Automation , Inc. with respect to use of information, circuits, equipment, or software described in this of the contents of this Manual , in whole or in part, without written permission of Rockwell Automation , Inc., is this Manual , when necessary, we use notes to make you aware of Safety may also be on or inside the equipment to provide specific precautions. WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic : Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss.

3 Attentions help you identify a hazard, avoid a hazard, and recognize the information that is critical for successful application and understanding of the HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE). Rockwell Automation Publication 1756-RM093J-EN-P - April 20183 Table of ContentsPrefaceSummary of Changes .. 7 Understanding Terminology.

4 7 Additional Resources .. 8 Chapter 1 Safety Integrity Level (SIL) ConceptSIL 3 Certification .. 11 Functional Verification Tests.. 12 GuardLogix Architecture for SIL 3 Applications .. 13 GuardLogix System Components.. 14 GuardLogix Certifications .. 16 GuardLogix PFD and PFH Specifications .. 16 Safety Integrity Level (SIL) Compliance Distribution and Weight.. 17 System Reaction Time .. 18 Safety Task Reaction Time .. 18 Safety Task Period and Safety Task Watchdog .. 19 Contact Information if Device Failure Occurs .. 19 Chapter 2 GuardLogix Controller System1756 GuardLogix Controller Hardware .. 21 Primary Controller .. 22 Safety Partner .. 22 Chassis .. 22 Power Supplies .. 221768 Compact GuardLogix Controller Hardware .. 23 CIP Safety Protocol .. 23 Safety I/O .. 23 Communication Bridges .. 24 Programming Overview.. 26 Chapter 3 CIP Safety I/O for the GuardLogix Control SystemOverview.

5 27 Typical Safety Functions of CIP Safety I/O Modules .. 27 Diagnostics .. 28 Status Data .. 28 Status Indicators.. 28On- or Off-delay Function .. 28 Reaction Time .. 28 Safety Considerations for CIP Safety I/O Modules.. 29 Ownership .. 29 Safety I/O Configuration Signature .. 29I/O Module Replacement .. 294 Rockwell Automation Publication 1756-RM093J-EN-P - April 2018 Table of ContentsChapter 4 CIP Safety and the Safety Network NumberRoutable CIP Safety Control System.. 33 Unique Node Reference .. 34 Safety Network Number .. 34 Considerations for Assigning the Safety Network Number (SNN) .. 35 Safety Network Number (SNN) for Safety Consumed Tags .. 35 Safety Network Number (SNN) for Out-of-box Modules .. 36 Safety Network Number (SNN) for Safety Module with a Different Configuration Owner.. 36 Safety Network Number (SNN) When Copying a Safety Project.

6 36 Chapter 5 Characteristics of Safety Tags, the Safety Task, and Safety ProgramsDifferentiate Between Standard and Safety .. 37 SIL 2 Safety Applications .. 38 SIL 2 Safety Control in the Safety Task .. 38 SIL 2 Safety Control in Standard Tasks (1756 GuardLogix controllers only) .. 41 SIL 3 Safety the Safety Task .. 41 Safety Task Limitations .. 41 Safety Task Execution Details .. 43 Use of Human-to-machine Interfaces.. 44 Precautions .. 44 Accessing Safety -related Systems .. 45 Safety Programs .. 46 Safety Routines .. 46 Safety Tags .. 47 Standard Tags in Safety Routines (tag mapping).. 48 Additional Resources .. 49 Chapter 6 Safety Application DevelopmentSafety Concept Assumptions .. 51 Basics of Application Development and Testing .. 52 Commissioning Life Cycle .. 53 Specification of the Control Function .. 54 Create the Project.

7 55 Test the Application Program .. 55 Generate the Safety Task Signature .. 55 Project Verification Test .. 56 Confirm the Project .. 57 Safety Validation .. 58 Lock the GuardLogix Controller.. 58 Downloading the Safety Application Program .. 59 Uploading the Safety Application Program .. 59 Online Editing .. 59 Storing and Loading a Project from Nonvolatile Memory .. 60 Force Data .. 60 Rockwell Automation Publication 1756-RM093J-EN-P - April 20185 Table of ContentsInhibit a Module .. 60 Editing Your Safety Application .. 61 Performing Offline Edits .. 62 Performing Online Edits .. 62 Modification Impact Test .. 62 Chapter 7 Monitor Status and Handle FaultsMonitoring System Status.. 65 CONNECTION_STATUS Data .. 65 Input and Output Diagnostics .. 66I/O Module Connection Status .. 66De-energize to Trip System .. 67 Get System Value (GSV) and Set System Value (SSV) Instructions 67 GuardLogix System Faults.

8 68 Nonrecoverable Controller Faults.. 68 Nonrecoverable Safety Faults .. 68 Recoverable Faults .. 69 Appendix ASafety InstructionsSafety Application Instructions .. 71 Metal Form Safety Application Instructions .. 72 Safety Instructions .. 73 Additional Resources .. 74 Appendix BSafety Add-On InstructionsCreating and Using a Safety Add-On Instruction .. 75 Create Add-On Instruction Test Project .. 77 Create a Safety Add-On Instruction.. 77 Generate Instruction Signature .. 77 Download and Generate Safety Instruction Signature .. 78 SIL 3 Add-On Instruction Qualification Test .. 78 Confirm the Project .. 78 Safety Validate Add-On Instructions .. 78 Create Signature History Entry .. 79 Export and Import the Safety Add-On Instruction .. 79 Verify Safety Add-On Instruction Signatures .. 79 Test the Application Program .. 79 Project Verification Test.

9 80 Safety Validate Project .. 80 Additional Resources .. 806 Rockwell Automation Publication 1756-RM093J-EN-P - April 2018 Table of ContentsAppendix CReaction TimesSystem Reaction Time .. 81 Logix System Reaction Time .. 81 Simple Input-logic-output Chain .. 82 Logic Chain Using Produced/Consumed Safety Tags.. 83 Factors Affecting Logix Reaction-time Components .. 84 Accessing Input Module Delay Time Settings .. 84 Accessing Input and Output Safety Connection Reaction Time Limit .. 85 Configuring the Safety Task Period and Watchdog .. 86 Accessing Produced/Consumed Tag Data .. 87 Additional Resources .. 88 Appendix DChecklists for GuardLogix Safety ApplicationsChecklist for GuardLogix Controller System .. 89 Checklist for Safety Inputs.. 91 Checklist for Safety Outputs .. 92 Checklist for Developing a Safety Application Program.. 93 Appendix EGuardLogix Systems Safety DataPFD Values.

10 95 PFH Values .. 96 Appendix FRSL ogix 5000 Software, Version 14 and Later, Safety Application InstructionsDe-energize to Trip System .. 97 Use Connection Status Data to Initiate a Fault Programmatically .. 97 Appendix GUsing 1794 FLEX I/O Modules and 1756 SIL 2 Inputs and Outputs with 1756 GuardLogix Controllers to Comply with EN 50156 SIL 2 Dual-channel Inputs (standard side of 1756 GuardLogix controllers) .. 103 SIL 2 Outputs Using SIL 3 Guard I/O Output Modules .. 105 SIL 2 Outputs Using 1756 or 1794 SIL 2 Output Modules .. 105 Safety Functions within the 1756 GuardLogix Safety Task .. 106 GlossaryIndexRockwell Automation Publication 1756-RM093J-EN-P - April 20187 PrefaceSummary of ChangesThis publication contains new and updated information as indicated in the following Manual is intended to describe the GuardLogix controller system, which is type-approved and certified for use in Safety applications up to and including SIL CL 3 according to IEC 61508 and IEC 62061, Safety applications up to and including Performance Level PLe (Category 4) according to ISO publication covers both 1756 and 1768 GuardLogix controller systems.